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General all-steel punching dies punching accuracy Author：John J. Craig Accuracy of panel punching part is display the press accuracy of the die exactly. But the accuracy of any punching parts linear dimension and positional accuracy almost depend on the blanking and blanking accuracy,. So that the compound mould of compound punchings accuracy, is typicalness and representation in the majority.Analyse of the dies accuracy For the analyse of pracyicable inaccuracy during production of dies to inactivation, we could get the tendency when it is augmentation in most time. From this we could analyse the elements. When the new punch dies pt into production to the first cutter grinding, the inaccuracy produced called initial error; if the die grinding more than twenty times, until its discard, the inaccuracy called conventional error; and before the dies discard, the largest error of the last batch permit, called limiting error. at job site, the evidence to confirm life of sharpening is the higher of the blanking, punched hole or punched parts. Because all finished parts had been blanked ,so it is especially for the compound dies. Therefore, the analyse of burr and measurement is especially important when do them as enterprise standardization or checked with . The initial error usually is the minimal through the whole life of die. Its magnitude depend on the accuracy of manufacture, quality, measure of the punching part, thickness of panel, magnitude of gap and degree of homogeneity. The accuracy of manufacture depend on the manufacture process. For the 1 mm thicked compound punching part made in medium steel, the experimental result and productive practice all prove that the burr of dies which produced by spark cutting are higher 25%30% than produced by grinder ,NC or CNC. The reason is that not only the latter have more exact machining accuracy but also the value of roughness Ra is less one order than the formmer, it can be reached 0.025m. Therefore, the dies initial blanked accuracy depends on the accuracy of manufacture, quality and so on. The normal error of the punch die is the practicable error when the fist cutter grinding and the last cutter grinding before the die produce the last qualified product. As the increase of cutter grinding, caused the measure the nature wear of the dies are gradual increasing, the error of punching part increase also, so the parts are blew proof. And the die will be unused. The hole on the part and inner because the measure of wear will be small and small gradually, and its outside form will be lager in the same reason. Therefore, the hole and inner form in the part will be made mould according to one-way positive deviation or nearly equal to the limit max measure. In like manner, the punching parts appearance will be made mould according to one-way negative deviation or nearly equal to limit mini measure. For this will be broaden the normal error, and the cutter grinding times will be increased, the life will be long. The limit error in punching parts are the max dimension error which practicable allowed in the parts with limit error. This kind of parts usually are the last qualified products before the die discard. For the all classes of dies, if we analyse the fluctuate, tendency of increase and decrease and law which appeared in the dies whole life, we will find that the master of the error are changeless; the error that because the abrade of the cutter and impression will be as the cutter grinding times increased at the same time. And that will cause the error oversize gradually; and also have another part error are unconventional , unforeseen. Therefore, every die s error are composed of fixed error, system error, accident error and so on. At the whole process when the New punching die between just input production to discard, the changeless master error that in qualified part are called fixed error. Its magnitude is the deviation when the die production qualified products before the first cutter grinding. Also is the initial error, but the die have initial punching accuracy at this time. Because of the abrade of parts, the die after grinding will be change the dimension error. And the increment of deviation will oversize as the times of cutter grinding. So the punching accuracy after cutter grinding also called “grinding accuracy” and lower tan initial accuracy. The fixed error depend on the elements factor as followed :1. the material , sorts, structure, (form) dimension, and thick of panel the magnitude of punching gap and degree of homogeneity are have a important effect for the dimension accuracy. Different punching process, material, thick of panel, have completely different gap and punching accuracy. A gear H62 which made in yellow brass with the same mode number m=0.34, 2mm thick and had a center hole, when the gap get C=0.5%t (single edge) , and punched with compound punching die, and the dimension accuracy reached IT7, the part have a flat surface ,the verticality of tangent plane reached 89.5, its roughness Ra magnitude are 12.5m, height of burr are 0.10mm; and the punching part are punched with progressive die, the gap C=7%t (single edge) , initial accuracy are IT11, and have an more rough surface, even can see the gap with eyes. In the usual situation, flushes a material and its thickness t is theselection punching gap main basis. Once the designation gap haddetermined flushes the plane size the fixed error main body; Flushesthe structure rigidity and the three-dimensional shape affects itsshape position precision.2. punching craft and molder structure type Uses the different ramming craft, flushes a precision and the fixederror difference is really big. Except that the above piece gearexample showed, the essence flushes the craft and ordinary punching flushes a precision and the fixed error differs outside a magnitude,even if in ordinary punching center, uses the different gap punching, thefixed error difference very is also big. For example material thickt=1.5mm H62 brass punching, selects C = the 40%t unilateral I kind ofsmall gap punching compared to select C 4mm flushes, the size precision can lower some. Different dies structure type, because is suitable the rammingmaterial to be thick and the manufacture precision difference, causesto flush a fixed error to have leaves. Compound die center, multi-locations continuous type compound die because flushes continuously toduplicate the localization to add on the pattern making error to bebigger, therefore it flushes a fixed error compound punching die to wantcompared to the single location Big 1 2 levels 3. the craft of punching dies manufacture the main work of punching die namely are raised, the concave moldprocessing procedure, to operates on the specification not to behigh, can time form a more complex cavity. But its processing surfaceapproximately is thick 0.03 0.05mm is the high temperatureablation remaining furcated austenite organization, degree ofhardness may reach as high as HRC67 70, has the micro crack, easilywhen punching appears broke the cutter or flaking. The Italian CorradaCorporations related memoir called the line cut the processing contruction to have the disadvantageous influence to the superficialgold, in fact already changed the gold contruction. We must use theJingang stone powder to grind or the numerical control continual pathcoordinates rub truncate (cut to line) to make the precision work . In recent years country and so on Switzerland and Japan, has conductedthe thorough research to the electrical finishing equipment and abigger improvement, makes function complete high accuracy NC and theCNC line cutter, the processing precision may reach 0.005 0.001mm,even is smaller. The processing surface roughness Ra value can achieve0.4 mu m. According to the recent years to the domestic 12 productionlines cutter factory investigation and study, the domesticallyproduced line cutter processing precision different factory differentmodel line cutter might reach 0.008 0.005mm, generally all in0.01mm or bigger somewhat, was individual also can achieve0.005mm, the processing surface roughness Ra value was bigger than1.6m. However, the electrical finishing ablation metal surface thus the change and the damage machined surface mental structure character can not change, only if with rubs truncates or other ways removes this harmful level. Therefore, merely uses electricity machining, including the spark cutting and the electricity perforation, achieves with difficulty punching, especially high accuracy, high life punching die to size precision and work components surface roughness Ra value request. With precisely rubs truncates the law manufacture punching die, specially makes the high accuracy, the high life punching die, such as: Thin material small gap compound punching die, multi- locations continuous type compound die and so on, has the size precision high, the work component smachined surface roughness Ra value is small, the mold life higher characteristic. Its processing craft at present changed the electrical fire by the past ordinary engine bed rough machining spark cutting or the electricity puncher rough machining, finally precisely rubs truncates, also from takes shape rubs, optics curve rubs, the manual grid reference rubs gradually filters the continual path grid reference to rub and NC and the CNC continual path grid reference rubs, Processing coarseness may reach 0.001 0.0005mm, the processing surface roughness Ra value may reach 0.1 0.025 mu m. Therefore, with this craft manufacture the die , regardless of the size precision, the work components surface roughness, all can satisfy die, each kind of compound request, the die is especially higher than the electrical finishing craft manufacture scale.4. gap size and degree of homogeneity the flange and other sheet forming sgene rally all must first punching (fall material) the plate to launch the semi finished materials, after also has the forming to fall the material, the incision obtains the single end product to flush. Therefore punching the work, including is commonly used punching hole, the margin, cut side and so on, regarding each kind of sheet pressing partall is necessary. Therefore punching the gap to flushes a out form in chprecision to have the decisive influence. punching the gap small and is even, may cause punching the size gain high accuracy. Regarding drawability, is curving and so on mould, the gap greatly will decide increases flushes the oral area size error and the snapping back. The gapnon-uniformity can cause to flush a burr enlarges and incurs cutting edge the non-uniform attrition. 5. ramming equipment elastic deformation In the ramming process After the punch press load bearing can have the certain elastic deformation. Although this kind of distortion quantity according to flushes the pressure the size to change also to have the obvious directivity, but on the pressing part, mainly is to has the volume ramming archery target stamping, embosses, the equalization, the pressure is raised, the wave, flushes crowds, the shape, the flange, hits flatly, thinly changes draw ability and so on the craft work punching forming flushes, has the significant influence to its ramming aspect size precision From: 黄河科技学院毕业设计(文献翻译) 第 4 页 普通全钢冲模的冲压精度 作者：约翰J克雷格 板料冲压件的精度准确显示出其冲模的冲压精度。而任何冲件的线性尺寸精度与形位精度主要取决于冲模冲裁和立体成形冲压件展开平毛坯的落料精度。因此，多工步复合冲压的单工位复合模、多工位连续模的冲压精度，在普通冲压的众多种类与不同结构的冲模中，最具典型性和代表性。冲模的冲压精度分析 对冲模投产至失效报废各个时期冲件的实际误差分析，可以看出其增大的时期及趋向，从而分析其增大的因素。新冲模投产至第一次刃磨前冲制冲件的误差即所谓的初始误差；冲模经过20次左右刃磨至失效报废前冲制的冲件误差称之为常规误差；而冲模失效报废前冲制的最后一批合格冲件的允许最大误差称之为极限误差。在现场，确定冲模刃磨寿命的依据是冲件冲孔与落料的毛刺高度。由于任何成形件都具有冲裁作业（毛坯落料或冲孔），对于复合模尤为如此。所以，冲件毛刺高度的触模检查和测量并按企业标准或JB4129-85冲压件毛刺高度对照检测就显得十分重要。 冲模的初始误差通常是冲模整个寿命中冲件误差最小的。其大小主要取决于冲模的制造精度与质量及冲件尺寸、料厚以及间隙值大小与均匀度。冲模的制造精度及质量又取决于制模工艺。对于料厚t1mm的中碳钢复合冲裁模冲件，实验结果与生产实践都证明，电火花线切割制造的冲模冲件毛刺高度比用成型磨或NC与CNC连续轨迹座标磨即精密磨削工艺制造的冲模冲件要高25%30%。这是因为后者不仅加工精度高，而且加工面粗糙度Ra值要比前者小一个数量级，可达到0.025m。因此，冲模的制造精度与质量等因素决定了冲模的初始冲压精度，也造就了冲件的初始误差。 冲件的常规误差是冲模经第一次刃磨到最后一次刃磨后冲出最后一个合格冲件为止，冲件实际具有的误差。随着刃磨次数的增加，刃口的自然磨损而造成的尺寸增量逐渐加大，冲件的误差也随之加大。当其误差超过极限偏差时，冲件就不合格，冲模也就失效报废。冲件上孔与内形因凸模磨损尺寸会逐渐变小；其外形落料尺寸会因凹模磨损而逐渐增大。所以，冲件上孔与内形按单向正偏差标允差并依接近或几乎等于极限最大尺寸制模。同理，冲件外形落料按单向负偏差标注允差并依接近或几乎等于极限最小尺寸制模。这样就使冲件的常规误差范围扩大，冲模可刃磨次数增加，模具寿命提高。 冲件的极限误差是具有极限偏差的冲件所具有的实际允许的最大尺寸误差。这类冲件通常是在冲模失效报废前冲制的最后一批合格冲件。 对各类冲模冲件误差在冲模整个寿命中出现的波动、增减趋向及规律等进行全面分析便可发现：冲件误差的主导部分是不变的；因刃口或型腔的自然磨损而出现的误差增量随冲模刃磨冲数增加而使这部分误差逐渐加大；还有部分误差的增量是非常规的、不可预见的。所以，各类冲模冲件误差是由因定误差、渐增误差、系统误差及偶发误差等几部分综合构成。 新冲模在指定的冲压设备上投入使用至失效报废的整个（总）寿命过程中，其合格冲件误差的主导部分固定不变即所谓固定误差。其大小就是新冲模第一次刃磨前冲制的合格冲件的偏差，也即冲模的初始误差，而此时的冲模具有初始冲压精度。刃磨后的冲模，因其工作零件（凸、凹模）磨损而改变尺寸误差，使冲件识差增量随刃磨次数增加而逐渐加大，故冲模刃磨后的冲压精度亦称“刃磨精度”比其初始精度要低。冲模冲件的固定误差取决于以下各要素：1、冲件的材料种类、结构（形状）尺寸及料厚 冲裁间隙的大小及其均匀度对冲裁件的尺寸精度有决定性的影响。不同冲裁工艺、不同材料种类与不等料厚，间隙相差悬殊，冲压精度差异很大。同一种模数m=0.34的2mm的料厚、中心有孔的H62黄铜材料片齿轮复合模冲件，当取间隙C=0.5%t（单边），用复合精冲模冲制，冲件尺寸精度达到IT7级，冲件平直无拱弯，冲切面垂直度可达89.5，其表面粗糙Ra值为0.2m；而用普通复合模冲制，间隙C=5%t（单边），冲件初始误差亦即冲模的初始冲压精度为1T9级，冲切面粗糙度Ra值为12.5m，毛刺高度为0.10mm；还是这个冲件用连续模冲制，间隙C=7%t（单边），初始冲件精度为IT11级，冲切面更粗糙，甚至有肉眼可见的台阶。通常情况下，冲件材料及其厚度t是选取冲裁间隙的主要依据。一旦选定间隙就确定了冲件的平面尺寸的固定误差的主体；冲件结构刚度及立体形状则影响其形位精度。2、冲压工艺及冲模结构类型 采用不同的冲压工艺，冲件的精度及固定误差相差甚大。除上述片齿轮实例说明，精冲工艺与普通冲裁的冲件精度与固定误差相差一个数量级之外，即便在普通冲裁中，采用不同间隙冲裁，固定误差相差也很大。例如料厚t=1.5mm的H62黄铜冲裁件，选用C40%t单边类小间隙冲裁比选用C8%t（单边）类大间隙冲裁，冲件固定误差将加大40%60%，精度至少降一级。此外，采有无搭边排样，冲件的误差要远大于有搭边排样冲件。无搭边排样冲件。无搭边排样冲件的精度低于IT12级，而多数有搭边排样的冲件精度在IT11IT9级之间，料厚t4mm的冲件，尺寸精度会更低一些。 不同冲模结构类型，由于适用冲压料厚及制造精度的差异，导致冲件的固定误差有别。复合模中，多工位连续式复合模由于冲件连续重复定位加上制模误差较大，故其冲件的固定误差比单工位复合冲裁模要 大12级。3、冲模制造工艺 冲模主要工作零件即凸、凹模的加工程序，对操作上的技术要求不高，能够一次成形较复杂的模腔。但其加工表面约厚0.030.05mm为高温烧蚀的残余树枝状奥氏体组织，硬度可高达HRC6770，有显微裂纹，容易在冲裁时出现崩刃或剥落。意大利Corrada公司的有关研究报告称“线切割加工对表面金相结构产生不利的影响，实际上已经改变了金相结构。我们必须用金刚石粉研磨或数控连续轨迹坐标磨削（对线切割件）作精加工”。近年来瑞士和日本等国，对电加工设备进行了深入的研究和较大的改进，制造出功能齐全的高精度NC和CNC线切割机，加工精度可达0.0050.001mm，甚至更小。加工表面粗糙度Ra值能达到0.4m。根据近年对国内12家生产线切割机工厂的调研，国产线切割机加工精度各别厂家的各别型号线切割机可达0.0080.005mm，一般都在0.01mm或更大一些，个别也能达到0.005mm，加工表面粗糙度Ra值均大于1.6m。然而，电加工烧蚀金属表面从而改变和损坏加工面金相结构的特性不会改变，除非用磨削或其他加工法去除这一有害层。所以，仅仅用电加工法，包括电火花线切割与电穿孔，难以达到冲模，尤其高精度、高寿命冲模对尺寸精度与工作零件表面粗糙度Ra值要求。 用精密磨削法制造冲模，特别是制造高精度、高寿命冲模，诸如：薄料小间隙复合冲裁模、多工位连续式复合模等，具有尺寸精度高、工作零件加工面粗糙度Ra值小、模具寿命高等特点。其加工工艺目前已由过去的普通机床粗加工改为电火花线切割或电穿孔机粗加工，最后精密磨削，也由成型磨、光学曲线磨、手动座标磨逐步过滤到连续轨迹座标磨及NC与CNC连续轨迹座标磨，加工粗度可达0.0010.0005mm，加工表面粗糙度Ra值可达0.10.025m。所以，用该工艺制造的冲模，无论尺寸精度、工作零件表面粗糙度，都能满足冲模，尤其各种复合模的要求，比电加工工艺制造的冲模高一个档次。4、间隙的大小与均匀度 拉深、弯曲、翻边及其他板料成形件一般都要先冲裁（落料）出平板展开毛坯，也有成形后落料、切开得到单个成品冲件。故冲裁作业，包括常用的冲孔、切口、切边等，对于每种板料冲压件都是必要的。所以冲裁间隙对冲件的外廓尺寸精度有决定性的影响。冲裁间隙小而均匀，可使冲裁尺寸获取更高精度。对于拉深、弯曲等成形模，间隙大定将增大冲件口部尺寸误差及回弹。间隙不均匀会使冲件毛刺加大并招致刃口的不均匀磨损。5、冲压设备的弹性变形 在冲压过程中，冲床承载后会产生一定的弹性变形。虽然这种变形量依冲压力的大小变化且具有明显的方向性，但就冲压件，主要是对具有体积冲压性质的压印、压花、校平、压凸、起波、冲挤、镦形、翻边、镦粗、打扁、变薄拉深等工艺作业冲制成形的冲件，对其冲压方面的尺寸精度有重大影响。 出自：科学指南 毕业设计文献翻译 院（系）名称工学院机械系 专业名称机械设计制造及其自动化 学生姓名郭中亮 指导教师 康红伟2012年 03 月 10 日 目 录前言1第一章 专业课程设计概述 2 1.1 专业课程设计的目的和要求 2 1.1.1 专业课程设计的目的2 1.1.2 专业课程设计的要求2 1.2 专业课程设计的内容3 1.2.1专业课程设计课题3 1.2.2 专业课程设计时间安排3 1.2.3 专业课程设计工作量4第二章 冷冲压工艺与模具设计、模具制造工艺4 2.1 冲压工艺性分析4 2.2 工艺方案确定5 2.3 确定模具类型及结构形式5 2.4 工艺计算6 2.5 编写工艺文件9 2.6 选择和确定模具主要零部件的结构和尺寸10 2.7 校核所选压力机11 2.8 编制工作零件机械加工工艺卡12第三章 塑料成型工艺与模具设计、模具制造工艺133.1 工艺分析14 3.2 成型设备的选择与模塑工艺参数的确定14 3.3 模具结构方案及尺寸的确定15 3.3.1选择制品的分型面15 3.3.2 型腔布置16 3.3.3浇注系统16 3.3.4 溢流、排气系统的设计17 3.3.5 选择脱模方式17 3.3.6 成型零件工作尺寸的计算17 3.3.7 模具主要零件的结构和尺寸设计18 3.3.8 模具调温系统的设置18 3.4 注射机有关工艺参数的校核19 3.5 编写工艺零件机械加工工艺20结束语21前 言在“十五”规划中，模具被认为是“工业生产的基础工艺装备”，国民经济的五大支柱产业机械、电子、汽车、石化、建筑都要求模具工业发展与之相适应。中国成模具制造大国当今世界正进行着新一轮的产业调整，一些模具制造逐渐向发展中国家转移，中国正成为世界模具大国。现代模具行业是技术、资金密集的行业。它作为重要的生产装备行业在为各行各业服务的同时，也直接为高新技术产业服务。模具是工业生产中使用广泛的基础工艺装备。有人说，现代模具是高技术背景下的工艺密集型工业。模具技术水平的高低，在很大的程度上决定着产品的质量、效益和新产品的开发能力，因此已成为衡量一个国家产品制造水平高低的重要标志。我国冲压模具无论在数量上，还是在质量、技术和能力等方面都已有了很大发展，但与国发经济需求和世界先进水平相比，差距仍很大，一些大型、精度、复杂、长寿命的高档模具每年仍大量进口，特别是中高档轿车的覆盖件模具，目前仍主要依靠进口。一些低档次的简单冲模，已趋供过于求，市场竟争激烈。同时，随着经济的发展注塑模具也飞速发展起来，因为注塑模优点很多。塑料具有质量轻、比强度大、绝缘性好、成型生产率高和价格低廉等特点。塑料已成为金属的子代用材料，出现了金属材料塑料化的趋势。2)由于汽车轻量化、低能耗的发展要求，汽车零部件的材科构成发生明显的以塑代钢的变化。从国内外汽车塑料应用的情况看，汽车塑料的用量已成为衡量汽车生产技术水平的重要标志。3)注塑成型由于可以一次成型各种结构复杂、尺寸精密和带有金属嵌件的制品，并目成型周期短，可以模多腔，大批生产时成本低廉，易于实现自动化生产，因此在塑料加行业中占有非常重要的地位。本设计是通过设计复合冷冲模和注塑模来熟悉模具设计与制造工艺，了解其内部的结构和工作原理，加深对所学习的知识的理解。由于本人所学模具知识水平有限，视野狭小,在设计中还存在这样那样的问题和错误，敬请老师批评指正。第一章 专业课程概述1.1专业课程设计的目的和要求专业课程设计是材料成型及控制工程专业教学中重要的实践教学环节之一，它是在冲压工艺于模具设计、塑料成型工艺于模具设计、模具制造工艺三门理论课程教学之后，为了加强学生所学的知识和提高学生的初步设计能力及实际动手能力二开设的实践性教学环节。1.1.1专业课程实际的目的 1、综合运用和巩固本课程及有关课程的基础理论和专业知识，培养学生从事模具设计于制造的初步能力，为后续毕业设计和实际工作打下良好的基础。 2、培养学生分析问题和解决问题的能力。经过课程设计环节，学生能全面理解和掌握冲压工艺、塑料成型工艺、模具设计、模具制造、等内容；掌握冲压工艺、塑料成型工艺、模具设计的基本方法和步骤、模具零件的常用加工方法及工艺规程的编制；独立解决在制定冲压工艺规程、设计模具结构、编制模具零件加工工艺规程中出现的问题；会查阅技术文献和资料，以完成从事本专业技术工作的人员在模具设计与制造方面所必须具备的基本能力训练。 3、在课程设计中，培养学生认证负责、踏实细致的工作作风和眼睛的科学态度，强化质量意识和时间观念，养成良好的职业习惯。1.1.2 专业课程设计要求 1、树立正确的设计思想，尽量结合生产实际，结合考虑技术性、经济性、实用性、可靠性、安全及先进性等方面的要求，严肃认真地进行设计。 2、独立拟定指定制件的成型工艺，正确选择成型设备。3、合理确定模具结构，很据制件图及模具要求，提出模具结构方案，并使其结构合理，质量可靠，操作方便。必要时可根据模具设计和加工要求，提出修改制件图纸的要求，但这必须征得用户同意后方可实施。4、正确确定模具成型零件的形状和尺寸。所设计的模具应当模具零部件加工工艺性好、制造方便、造价便宜、装配调整、维护维修方便。模具使用效率高，安全可靠，使用寿命长。5、充分考虑制件的设计特色，尽量减少后加工工序。 6、要求所编制的模具零件加工工艺规程符合生产实际，技术经济性。 7、设计说明书要求文字通顺、条理清晰、书写工整。图纸图面整洁、标注齐全、图样及标注符合国家标准。1.2 专业课程设计的内容1.2.1 专业课程设计课题专业课程设计所用的制件尽量从生产实践中选取，要求该零件具有一定的典型意义。冲压模具课题：选用只有两道工序的制件，拟定用冲孔落料复合模或两道工序的连续模作为制件的成型方法，设计模具、编写模具工作零件的加工工艺作为设计题目。塑料模具课题：选择无侧向抽芯的塑料件，拟定用注射模成型的方法，设计模具、编写模具工作零件的加工工艺作为设计题目。1.2.2专业课程设计时间安排表1.1 专业课程设计安排表项目工艺与设计画装配图画零件图编制模具制造工艺卡片整理、答辩冲裁模2-3天2.5天1-1.5天0-1天2天注射模2-3天2.5天1-1.5天0-1天2天1.2.3 专业课程设计工作量1、冲裁模具、塑料注塑模具装配图各一张。2、冲裁模具、塑料注射模具工作零件图。3、冲模、塑模工作零件（各一份）机械加工工艺卡各一份（附在说明书）。4、模具设计说明书一份，字数要求10000-15000字。第二章 冷冲压工艺与模具设计、模具制造工艺工件如下图，材料Q235，料厚1mm，表面不允许有明显的划痕。技术要求：1 未注圆角为R1 2 未注公差为IT14级 3 材料厚度t=1mm图2.1 制件图2.1 冲压工艺性分析1、材料：该零件的材料为Q235，是普通的碳素工具钢，板厚为1mm，具有良好的可冲压性能。 2、该零件的形状比较简单、规则，并在转角处有R1的圆角过渡，孔边距较大，且孔的尺寸是8，工艺性较好。 3、尺寸精度，零件上所有孔的位置精度为IT12IT14，尺寸精度为IT13，其余尺寸都是未注公差，属于自由公差，精度比较低，符合冲裁件的工艺性要求。查公差表可以得到如图所示的结果。结论：适合冲压。2.2 工艺方案确定该工件包括落料、冲孔另个基本工序：方案一：先落料，后冲孔，采用单工序模生产。方案二：落料冲孔复合冲压，采用复合模生产。方案三：冲孔落料级进冲压，采用级进模生产。方案一模具结构简单，但需要两道工序两副模具，成本高而生产率低，难以满足大中批量生产需求。方案二只需一副模具，工件的精度及生产效率都很高。方案三也只需一副模具，生产效率高，操作方便，但位置精度不如复合模具冲裁精度高。通过对以上三种方案的分析比较，成型该零件采用方案二复合模具成型。2.3 确定模具类型及结构形式1、该零件质量要求不高，板厚1mm，孔边距较大,为了保证零件的精度，可以选用正装复合模。2、定位方式的选择：控制条料的送进方向采用两个导料销，控制条料的送进步距采用挡料销。3、卸料、出件方式的选择：采用弹性卸料、上出件，下模刚性顶件。4、导向方式的选择：为了方便操作，该模具采用后侧导柱的导向方式。 冲压件的形状简单，精度要求也不高，为了使得模具的寿命较高，采用有导向、弹性卸料、下出件的模具结构形式。2.4 工艺计算 1、确定最佳排样方式，并计算材料利用率，选择板料的规格。 该零件为较规则的矩形零件，可直接设置为斜排排样方式，如图：图2.2 查冲压手册表218，最小搭边值为：工件间2mm 侧面1.5mm工件面积：1171.2mm2斜排：取搭边值1.2mm条料宽度：B=57.45mm 步距：L=36mm材料利用率：=1171.2/（57.4536）=56.6选用12500mm1250mm,可以裁43条，每条可以冲34件。总的材料利用率：43341171.2/(25001250)=552、计算冲压合力并预选冲床L=145mm+37.7mm=182.7mmt=1mm =450MP冲压力：F=Lt=182.71450=82.2KN查冲压工艺及模具设计表3-11 K=0.05 K=0.055 K=0.06卸料力：F= KF=0.0582.2KN= 4.1KN正装复合模：顶件力F顶 = KF=0.0682.2=5KN冲裁合力F=FKF=91.3KN根据冲压合力预选 J23-16的曲柄压力机3、确定冲裁压力中心先求xx1=0 x2=4.5 x3=9 x4=17 x5=25 x6=33.5 x7=42 x8=50 x9=58x10=51.5 x11=45 x12=41.5 x13=38 x14=29 x15=20 x16=16.5 x17=13 x18=6.5 x19=13 x20=45L1=28 L2=9 L3=8 L4=16 L5=8 L6=17 L7=8 L8=16L9=36 L10=13 L11= 8 L12= 7 L13=8 L14=18 L15=8L16=7 L17=8 L18=13 L19=L20=8x=x iLi/Li=8444.96/286.2=29.5再求yy1=14 y2=28 y3=32 y4=36 y5=32 y6=28 y7=32 y8=36 y9=18 y10=0 y11=4 y12=8 y13=4 y14=0 y15=4 y16=8 y17=4 y18= 0 y19=18 y20=18y=yi Li/Li=4832.32/286.2=16.93 取x=29.5mm y=17